Offshore Intercooler Upgrade.

For many years now we have been sitting on a Intercooler kit.
From many hours of testing the R&D kit and the home made version with hardware store stuff we found a better method.
In fact we liked it so much we kept it a secret as to our own method of upgrading cooling.
Lets just start with the basics.
This method ovoids drilling thru the hull in the pump box area. It also produces true dual feeds to the intercooler improving flow, not some dual feed off one line slowing flow.
Testing and data logging show a max air charge of 290 F was brought down to 108 F using my method. This data is similar and at times better then the R&D kit without the additional holes or expense.

List of parts needed.
13″ of 1/2 hose $3 {Yellow 13}
3″ of 5/8 hose $1 {Yellow 3}
4 stainless hose clamps $5 {Silver looking hose clamps}
1 Plastic 1/2 to 5/8 in line reducer $1.5 {Pink #2}
1 Billet 1/2 thru hull 90 deg fitting $14.95 {Orange #3}
1 1/8 NPT plug. $1 {Blue A}

Total cost of $35 if done the way we’ve been doing it. Some warnings at the bottom in the method we have been forced to do it. Please read them under Warning!.

This pictures shows the internal water routing divide. Its the green line, internally the intercooler is divided for water to flow from back side “A” of green line to up and over to flow down the front side “B” to the exit in lower front side. Red arrows show stock water flow thru the intercooler. Our way of routing the water will now be Red arrows on A side and yellow arrows on B side.
This has proven over and over to be a more consistent result in intercooler performance especially in long running applications.
Lets explain the simple way to do it.
Starting inside the craft. Remove the waterline from the exhaust manifold to the top of intercooler. Save this waterline and hose clamp as it is needed. See pic below of fitting removed and brass lug inserted.

I know what your thinking, yes this can be done inside the craft, no you don’t need to remove the entire exhaust to get to this fitting. Its a demo piece.
Blue A is the plug and Green B is the needed fitting for the pump. Why? Its a restricted fitting that is crucial in regulating intercooler pressure and flow.
We do this as shown below, this gives a total of two restricted inlets into the two bottom halves of the intercooler and allowing a larger outlet of the top of the intercooler.

The intercoolers new drain is going to use the 1/2 thru hull fitting. See pic below. I used the hose from the manifold, in fact in this pic it shows you don’t even need to remove it from the intercooler. Just remove it from the exhaust manifold and route it out the thru hull you installed. Then plug the manifold with lug and use the barbed fitting on the pump.

Moving onto the pump area.
Removing ride plate and exit nozzle makes access alot easier .

Red #1 was the stock drain for the intercooler. Now it will become the second input to the bottom of the intercooler. Simply route the drilled and taped water bar fitting #2 into the thru hull #1. Do this by using the brass fitting off the exhaust manifold that is a regulated or restricted fitting. This fitting is 1/2 in but the thru hull is 5/8. Use the plastic fitting here with the 1/2 and 5/8 rubber hoses.
Drill and tapping water bar with Exhuast manifold restricted brass fitting.

Looks like this when done.

Be sure to use hose clamps, the above pics was just a demo shot.!!!
Here comes the warning!!!!!
We used a plastic 5/8 to 1/2 reducer. This needs to be billet or brass. Wait one is coming real soon. We’ve bugged the crap out of people to make one.
Also when drilling the water bar the material isnt that thick and the thread could come loose and blow the fitting out. Trust me its happened to us. Again a Billet water bar is coming too as we bugged the crap out of them for this too.
Here is the good news, If the water bar should blow out the fitting or the reducer crack or fail, there will be no danger to your craft or motor, It just means the flow will revert to stock flow pattern with a reduced exit from the thru hull. This reduced pressure will let you know one of the above has happened.